Swapping my 454 with a 502 in a 22 Scarab
 

Tore the Scarab apart last night... wow... when you pull all the panels off you see what a shotty job they do putting it together... sloppy cuts in the fiberglass...etc.

Once I have the engine pulled, I will swap the accessories over to my new 502... I have to install the Trim tabs and the Hydro Steering. To my suprise I have rack and pinion steering (So I gues that is a partial internal hydraulic)... Still waiting on the Holley 850 and intake, exhaust manifold will be purchased this weekend.

First question:
The engine I bought was balanced and built without the flywheel that was origianaly on the boat... The engine was internaly balanced when built, what do I need to do about my flywheel? Can I just sandblast it and remount it? Are there going to be balance issues?

Second Question:
Due to concerns about reversion and cost savings I am going to ditch my attempts to add captins call to what was once only through prop exhaust. I am pulling our the through prop exhaust and installing through transom... what do I need to do to cap the old through prop setup?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

you either need a neutral balanced flywheel ....or have your old one rebalanced to neutral ....Some say its better to buy new ...

and dont forget the Harmonic Balancer also ....

Re: Swapping my 454 with a 502 in a 22 Scarab
 

I know exactly what you mean. I thought the same thing when tore my 27' Carrera apart. I always thought it would look something like taking a new car apart (everything new looking inside the internals. Instead mine had the look of a badly frame house.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Yea it did... I will post some pictures up of it tomorrow.

As for the flywheel... it still has the weight on it and the harmonic balancer from the original motor.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

When it comes time, consider us for your exhaust please.

www.atecoengines.com

Good luck with your project! :drink:

Re: Swapping my 454 with a 502 in a 22 Scarab
 

if you did not "zero" balance the flywheel and use neutral HB ... those are not good things .... I would get someone's advice on that ....m

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Dont take chnaces on the flywheel. Have it resurfaced and zero balanced . You wont be sorry that way.
Blocking off the old exhaust is easy once the engine is out. Just get a 'Y' pipe block off plate from Merc and throw the 'Y' pipe away. Make sure you get a good seal on that block off plate.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

I have been considering the same swap in a 22 Scarab. I am concerned with sunpad clearance. Yes, Pic's Doug

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Well I was able to pull the motor without having to remove the outdrive. Just needed to pull the sundeck and the seats.

It is raining on me now so I cant keep working on cleaning her up... I will go snap a few pics though.

Ok someone help me out.... where can I find the replacement plastic fitting that holds down the thermostat in the thermostat housing? (see pic)

Re: Swapping my 454 with a 502 in a 22 Scarab
 

So you were able to pull it straight forward a good bit to disengage the drive input shaft?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

I had to remove the belt drive wheel from the front of the Harmonic Balancer to get enought room... but yep I was able to.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

You still have to remove the drive. You have to align the engine after you drop it in.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Here is a picture of the Scarab with the 330 Merc removed.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

thermostat housing
Any Marine Center.

Looks like alot of work to pull the engine without taking the drive off. You must of used an overhead hoist.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Jim... actully it was suprisingly easy, but yea we did use an overhead hoist.

Checkmate what does aligning the engine require? If I use the same motor mounts and the engine slides onto the driveshaft... isnt that aligned?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Ok guys... I am begining to get the feeling that I am missing something huge here? The removal of the engine was easy... the new engine is comming together fast. The outdrive is still in place and the same engine mounts are on the new motor. Can I simply slide the new motor back onto the drive shaft? I am sure that someone will say no... but please explain why!

If I could have afforded to have this done professionaly I would have... but I would have had to wait untill I returned from my second tour in Iraq. So I decided to take a crack at it. I know I sound like a noob here... I am one. Just trying to get it right the first time!!

Thanks all!!
Jared

Re: Swapping my 454 with a 502 in a 22 Scarab
 

While you may be able to just slide the engine back in place without removing the drive, it is not the right way to do it. Dont think anyone here will disagree with me on this one.
You should align the engine with the drive to do it right.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Hmmm ok well crapola. If anyone knows of a good online instruction on how to do this... or someone in central TX willing to help for a small fee... I would be indebted.

Jared

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Aligning the engine is pretty easy, but you need the merc. alignment tool. All the tool does is make sure the gimbal bearing in the transom assembly is aligned with the engines coupler. When the tool slides thru the gimbal bearing and into the coupler smoothly and without binding the engine is aligned. You can probably use the drives yoke by taking it off the drive if you dont want to buy a alignment tool. If you do this pull the o-rings off the yoke so you dont get a false feeling of binding. Putting everything back in the way it came out is where you need to start, If the tool or yoke binds, you just need to adjust your motor mts up/dn, or left/right untill it slides in smoothly.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Trust me on this. It will be so much easier to just pull out your outdrive before you drop in your engine. It takes 10 mins to pull it out. 6 nuts is all that holds it on. I can pull mine off faster then I can change a tire. That is the reason why you hear about so many people that have gotten the outdrive stolen, because it is so easy.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Ok that being said... I think I will remove the outdrive! :D

When I remove the outdrive are there any required gaskets to put it back? Any maint I need to do while its out? Any tips to its removal?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

There is a gasket set (more of an o-ring set) for drive removal. It's under $10. From West Marine or any Merc dealership.

1st thing is to raise the drive and unhook the speedo tube. Turns a few degrees, then lifts up.. Lower drive back down, remove 5 of the 6 nuts, remove the trim cyl rod, remove last nut, pull drive straight back and out.

Grease the u-joint, inspect the bellows for cracks.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Can I lay it on its side or does it need to remain standing up?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Laying it down is fine.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Ok got it.. have someone from the local boat shop that will help me align the motor for a case of beer (I am buying the alignment tool for 50 bucks off e-bay)... Most the parts are here. I am getting close!!

I still need a good answer on this motor balance problem.... The block was built with the harmonic balancer and all balanced... I have the original flywheel that is weighted (matched to the harmonic balancer)... do I need to nuturalize it or leave it as is? Is there a way to test balance on an assembled motor?

Thanks guys!!!

Re: Swapping my 454 with a 502 in a 22 Scarab
 

The motor is balanced 2 ways .. either external or internal ..who ever built the motor should be able to tell you. If its internally balanced you will need NEW flywheel and HB ... If the motor is externally balanced you can use the stock parts .....

I have "heard" to make sure you use a "merc" alignment tool ..... not a generic one ... I dont know for sure ...I'm sure someone will chime in ........

Re: Swapping my 454 with a 502 in a 22 Scarab
 

A good machine shop can balance your flywheel to neutral.
They can also bolt two flywheels together and match their weight.
So they can make yours the same (in this case neutral) balance as another neutral flywheel. It's been done many times. I just had one done from external to neutral for a 588 Motor. BBB

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Oh , the dampener would be same as a 427 if internal balance

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Billy .. how much it cost you to balance the flywheel ? Thats the only problem I have heard thats its usually the time it takes a machinist to do the job ..can run as much as a new one ....but thats what I have "heard" ..dont know for sure ...

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Still need help on this one... I bought what I thought was the replacement plastic ring for this.... I was wrong. Any idea as to the part #?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Longrange4u, this is all good info you are getting. Once the drive is off, reach in the back of the boat and spin the gimble bearing to make sure it is still good. It spins firmly but should be smooth. If it is bad you will feel it catching or loose as you spin it. Grease it and the u-joints.
Also look at the drive coupler where the splines of the outdrive goes into it. The splines should have a somewhat square tip on them like the outdrive shaft and not pointed. If they are pointed then it is getting worn out and now is the right time to replace it. I would hate to see you install your new motor and go testing just to have the splines stip out and have to pull the motor to replace it.
The part number of the plastic sleeve is 23-806922.
You can find just about any part # at this web site and order from there also. I have ordered many parts from BAM Marine and they do a good job.
http://www.mercruiserparts.com/

Good luck!

Re: Swapping my 454 with a 502 in a 22 Scarab
 

I too swapped my 454 for a 502. I was swapping MPI engines which is a little different but worked great. Its easier than you think. All the previous info is exactly what you need to do. When you get to prop selection I tried many. The best I found was a labbed 25 Mirage Plus. Should put you 72 to 74 mph GPS. It's a lot more fun to drive with the 502 :D

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Wow guys great info... another question... there are two Mercrusier external water pumps. I purchased the later model (newer version) and it bolted right up to my pump fine... then upon closer inspection I have the older version. After much inspection and comparison, other then the housing shape and being a one piece instead of two... the function looks the same and it fit fine on my housing... do I need to buy the older two piece version?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

no.....

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Hmmmm ok... got the engine alignment tool. Valvecovers came in, new marine stereo came in. Going to install the RR and valve covers next weekend, maybe the exhaust, and may even go as far as set the motor in...

Ohhh I bought a used WPM hydro steering setup for 850$ too.. that is soon to go on as well.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

What are you going to do with the 454?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

If you didn't already get a flywheel Summit has the one you need for $114.00. That is the one I purchased for my new 502 Crate engine that is externally balance. The flywheel is GM PERFORMANCE BRAND.

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Gonna rebuild and sell the 454...... forged pistons, tighten her up some and make some of my money back that I have sank into this money pit. (I will also be how I pay my buddy for helping me)

Vandeano.... thanks for the info but my challange is that my engine was supposed to have been internaly balanced....

Re: Swapping my 454 with a 502 in a 22 Scarab
 

Well good... I got a WPM hydro steering set from ebay for 800$... that saved me some bucks on my budge build (is there such a think with a boat?). We are in an exercise preparing to go back to Iraq at the end of the year so it is hard to put more time into the build... I talked to the builder and a couple others. Because I have the original Flywheel with the motor, with the original harmonic bal... It has been suggested that I use that. What do you guys think? I looked at summit for the flywheel you talked about van but it is for external balance... didnt say anything about being nuturalized. Whats the diff in a flywheel and flexplate?

Re: Swapping my 454 with a 502 in a 22 Scarab
 

To my understanding it should be at neutral. Flexplate I think is for a automatic transmission hook up. Not what u need.